US20150030399A1 - Coupling mechanism for cutting tool - Google Patents
Coupling mechanism for cutting tool Download PDFInfo
- Publication number
- US20150030399A1 US20150030399A1 US14/273,456 US201414273456A US2015030399A1 US 20150030399 A1 US20150030399 A1 US 20150030399A1 US 201414273456 A US201414273456 A US 201414273456A US 2015030399 A1 US2015030399 A1 US 2015030399A1
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- US
- United States
- Prior art keywords
- axial
- shank
- cutter member
- cutter
- threaded portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000005520 cutting process Methods 0.000 title claims abstract description 87
- 230000008878 coupling Effects 0.000 title description 22
- 238000010168 coupling process Methods 0.000 title description 22
- 238000005859 coupling reaction Methods 0.000 title description 22
- 230000007246 mechanism Effects 0.000 title description 18
- 238000005304 joining Methods 0.000 claims description 3
- 239000011295 pitch Substances 0.000 description 85
- 230000004323 axial length Effects 0.000 description 16
- 239000000463 material Substances 0.000 description 14
- 229910000831 Steel Inorganic materials 0.000 description 11
- 239000010959 steel Substances 0.000 description 11
- 239000007787 solid Substances 0.000 description 8
- 230000013011 mating Effects 0.000 description 7
- 230000002860 competitive effect Effects 0.000 description 4
- 230000000295 complement effect Effects 0.000 description 4
- 238000005094 computer simulation Methods 0.000 description 4
- 230000036316 preload Effects 0.000 description 4
- 239000002826 coolant Substances 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000003801 milling Methods 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000005489 elastic deformation Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2251/00—Details of tools for drilling machines
- B23B2251/02—Connections between shanks and removable cutting heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B31/00—Chucks; Expansion mandrels; Adaptations thereof for remote control
- B23B31/02—Chucks
- B23B31/10—Chucks characterised by the retaining or gripping devices or their immediate operating means
- B23B31/11—Retention by threaded connection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B51/00—Tools for drilling machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/02—Connections between the shanks and detachable cutting heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/03—Cutting heads comprised of different material than the shank irrespective of whether the head is detachable from the shank
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2240/00—Details of connections of tools or workpieces
- B23C2240/32—Connections using screw threads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
- B23C5/109—Shank-type cutters, i.e. with an integral shaft with removable cutting inserts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B39/00—Locking of screws, bolts or nuts
- F16B39/22—Locking of screws, bolts or nuts in which the locking takes place during screwing down or tightening
- F16B39/28—Locking of screws, bolts or nuts in which the locking takes place during screwing down or tightening by special members on, or shape of, the nut or bolt
- F16B39/30—Locking exclusively by special shape of the screw-thread
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T407/00—Cutters, for shaping
- Y10T407/19—Rotary cutting tool
- Y10T407/1906—Rotary cutting tool including holder [i.e., head] having seat for inserted tool
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T408/00—Cutting by use of rotating axially moving tool
- Y10T408/89—Tool or Tool with support
- Y10T408/907—Tool or Tool with support including detailed shank
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T408/00—Cutting by use of rotating axially moving tool
- Y10T408/89—Tool or Tool with support
- Y10T408/909—Having peripherally spaced cutting edges
- Y10T408/9098—Having peripherally spaced cutting edges with means to retain Tool to support
Definitions
- the present invention relates to coupling mechanisms for use with rotary cutting tools and, more particularly, to rotary cutting tools including such coupling mechanisms.
- end mills for metal cutting machinery were produced as a single unit, comprising a fluted cutting portion and a cylindrical or conical shank portion sized to fit a machine spindle.
- increasing global pricing of modern tool alloys along with recently developed intricate surface treatments have made such single units less economical, as the expensive shank material is generally wasted. It has therefore became common practice to produce a separate cutter made of high quality alloy or sintered carbide, which is then concentrically attached to the end of a reusable steel shank.
- each replacement cutter be repeatedly, accurately, centered to the true spindle axis of rotation and axially positioned correctly.
- U.S. Pat. No. 5,114,286 which teaches an interchangeable cutting tool alignment and positioning system comprising a first tool segment having a male coupler and a second tool segment having a female coupler.
- the male coupler comprises a pilot in the form of first cylindrical mating surface, a concentric aligner in the form of second cylindrical mating surface spaced apart from the pilot, a male thread extending between the pilot and the concentric aligner and an axial stop in the form of planar surface.
- the female coupler comprises a pilot bore in the form of complementary cylindrical mating surface, corresponding to the cylindrical mating surface of the pilot, a concentric bore in the form of a complementary cylindrical mating surface corresponding to the cylindrical mating surface of the concentric aligner, a female thread extending between the pilot bore and the concentric bore, and an axial stop in the form of complementary planar surface.
- pilot, concentric aligner, pilot bore and concentric bore are necessary because the threaded coupler by its own is not sufficiently accurate for such repeated replacement of cutters.
- sintered carbide cutters by their nature are very hard yet also very brittle. Direct coupling of the hard cutter to the steel shank imposes stresses on the coupling where the two different materials engage. More particularly, in cases where a carbide cutter is threaded into a steel shank, failure of the connection is likely to occur at or near the base of the threaded portion of the carbide cutter, which commonly also damages the steel shank, rendering it unsuitable for reuse.
- a rotary cutting tool comprises a cutter of generally cylindrical shape disposed about a central longitudinal axis.
- the cutter includes a first end having an active fluted portion and an opposite second end, the second end having a male threaded portion disposed thereabout.
- the rotary cutting tool further comprises a shank of generally cylindrical shape disposed about the central longitudinal axis, the shank having a recessed female threaded portion formed in a first end.
- the male threaded portion includes a number of threads disposed at a first pitch and the female threaded portion includes a number of threads disposed at a second pitch different than the first pitch.
- the cutter and the shank are selectively coupled via threaded engagement of the male threaded portion and the female threaded portion.
- the first pitch may be less than the second pitch.
- the first pitch may be about 0.005 mm less than the second pitch.
- the difference between the first pitch and the second pitch may be in the range of about 0.002 to about 0.010 mm.
- the cutter may be formed from a carbide material and the shank may be formed from a tool steel.
- the cutter may comprise an outward facing circumferential surface extending a distance along the central longitudinal axis disposed between the active fluted portion and the male threaded portion
- the shank may comprise an inward facing circumferential surface extending a distance along the central longitudinal axis between the female threaded portion and the first end of the shank
- the outward facing circumferential surface may be disposed adjacent to, and facing the inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged.
- the outward facing circumferential surface may be generally in the form of a portion of a truncated cone disposed at a first angle with respect to the central longitudinal axis and the inward facing circumferential surface may be generally in the form of a portion of a truncated cone disposed at a second angle with respect to the central longitudinal axis.
- the first angle may be in the range of about 1° to about 7°.
- the second angle may be in the range of about 1° to about 7°.
- the outward facing circumferential surface may be generally a cylindrical surface disposed parallel to the central longitudinal axis and the inward facing circumferential surface may be generally a cylindrical surface disposed parallel to the central longitudinal axis.
- the cutter may comprise an outward facing circumferential surface extending a distance along the central longitudinal axis disposed adjacent the male threaded portion and opposite the active fluted portion
- the shank may comprise an inward facing circumferential surface extending a distance along the central longitudinal axis adjacent the female threaded portion opposite the first end of the shank
- the outward facing circumferential surface may be disposed adjacent to, and facing the inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged.
- the outward facing circumferential surface may be disposed at an angle in the range of 0° to about 6° with respect to the central longitudinal axis.
- the inward facing circumferential surface may be disposed within the range of 0° to 2° of the angle of the outward facing circumferential surface.
- the cutter may comprise a first outward facing circumferential surface extending a distance along the central longitudinal axis disposed between the active fluted portion and the male threaded portion and a second outward facing circumferential surface extending a distance along the central longitudinal axis adjacent the male threaded portion and opposite the active fluted portion
- the shank may comprise a first inward facing circumferential surface extending a distance along the central longitudinal axis between the female threaded portion and the first end of the shank and a second inward facing circumferential surface extending a distance along the central longitudinal axis adjacent the female threaded portion opposite the first end of the shank
- the first outward facing circumferential surface may disposed adjacent to, and facing the first inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged
- the second outward facing circumferential surface may be disposed adjacent to, and facing the second inward facing circumferential surface when the male threaded portion and the female threaded portion are threade
- a rotary cutting tool comprises: a cutter of generally cylindrical shape disposed about a central longitudinal axis, the cutter having a first end having an active fluted portion and an opposite second end, the second end having a male threaded portion disposed thereabout; and a shank of generally cylindrical shape disposed about the central longitudinal axis, the shank having a recessed female threaded portion formed in a first end.
- the male threaded portion includes a number of threads disposed at a first pitch and at a first taper angle
- the female threaded portion includes a number of threads disposed at a second pitch and at a second taper angle different than the first taper angle
- the cutter and the shank are selectively coupled via threaded engagement of the male threaded portion and the female threaded portion.
- the first taper angle may be less than the second taper angle.
- the first pitch may be equal to the second pitch or the first pitch may be less than the second pitch.
- FIG. 1 shows an isometric view of an example embodiment of a modular rotary cutting tool in accordance with the present invention.
- FIG. 1B shows a side view of the modular cutting tool of FIG. 1 with the shank portion shown in cross-section.
- FIG. 2 shows an exploded isometric view of the modular cutting tool of FIG. 1 .
- FIG. 3 shows an exploded side view of the modular cutting tool of FIG. 1 with the shank portion shown in cross-section to show internal details.
- FIG. 4 shows a detail side view of the cutter portion of the rotary cutting tool of FIG. 1 .
- FIG. 5 shows a detail cross-sectional view of a portion of the shank portion of the rotary cutting tool of FIG. 1 .
- FIG. 6 shows a side view of another example embodiment of a coupling mechanism in accordance the present invention shown partially in cross-section to show internal details.
- FIG. 7 shows an exploded side view of another example embodiment of a modular cutting tool in accordance with the present invention with the shank portion shown in cross-section to show internal details.
- FIG. 8 is a side view of the shank portion of another specific embodiment of a rotary cutting tool.
- FIG. 9 shows a cross-sectional view of the shank portion of FIG. 8 taken along section line 9 - 9 of FIG. 8 .
- FIG. 10 is an enlarged view of a portion of the shank portion of FIG. 9 encompassed by the circle designated as 10 in FIG. 9 .
- FIG. 11 is an enlarged view of the portion of the shank portion of FIG. 10 encompassed by the circle designated as 11 in FIG. 10 .
- FIG. 12 is an enlarged view of the portion of the shank portion of FIG. 10 encompassed by the circle designated as 12 in FIG. 10 .
- FIG. 13 is a side view of the replaceable cutter member.
- FIG. 14 is a cross-sectional view of the replaceable cutter member taken along section line 14 - 14 of FIG. 13 .
- FIG. 15 is an enlarged view of the replaceable cutter member encompassed by the circle designated as 1 in FIG. 14 .
- FIG. 16 is photograph of a competitive cutter member made by Sandvik.
- FIG. 17 is photograph of a competitive cutter member made by Iscar.
- FIG. 18 is photograph of a competitive cutter member made by Fraiza.
- FIG. 19 is graph showing results of a computer simulation wherein the maximum principle stress (MPa) under preload at each of five different threads of four different cutter members as described in more detail hereinafter wherein thread 1 is the thread closest to the cutting region of the cutter member and thread 5 is closest to the rear end (or tail) of the cutter member.
- MPa maximum principle stress
- FIG. 20 is graph showing results of a computer simulation wherein the maximum principle stress (MPa) under preload and bending at each of five different threads, if applicable, of six different cutter members as described in more detail hereinafter wherein thread 1 is the thread closest to the cutting region of the cutter member and thread 5 is closest to the rear end (or tail) of the cutter member.
- MPa maximum principle stress
- number shall refer to any non-zero quantity (i.e., one or any quantity greater than one).
- selectively coupled shall mean that two or more components are coupled or joined together in a manner which may be selectively undone (i.e., uncoupled) without damaging either of the components.
- the term “pitch” shall refer to the distance measured parallel to a central axis of a threaded member between corresponding points on adjacent thread forms in the same axial plane and on the same side of the axis.
- FIGS. 1-5 show a modular rotary cutting tool 10 according to a first example embodiment of the invention disposed about a central longitudinal axis A.
- Cutting tool 10 includes a reusable shank 12 and a replaceable cutter 14 , selectively coupled together by a coupling mechanism (not numbered) formed from cooperating portions of each of shank 12 and cutter 14 which are discussed in detail below.
- a coupling mechanism not numbered
- cutter 14 is in the form of an end mill formed from a carbide material, however, it is to be appreciated that another rotary cutting tool, e.g., without limitation, a face mill, rounded tip mill, slitting mill, drill, reamer, or any other replaceable tip for milling, drilling, reaming or other metal cutting applications, formed from carbide or other suitable material or materials may be employed without varying from the scope of the present invention.
- Shank 12 may be formed from steel, carbide or other suitable material formed in a generally cylindrical shape with a slightly stepped portion, however, it is to be appreciated that other cross-sections, shapes, and materials may also be employed without varying from the scope of the present invention.
- shank 12 may be formed as a generally solid member, as shown in the illustrated embodiment of FIG. 1-5 , or may include one or more internal passages through which a flow of coolant and/or lubricant may be provided to cutter 14 .
- the exposed portion of the cutter 14 may include an active fluted portion 16 structured to perform cutting operations on a workpiece (not shown), followed by a short cylindrical portion 18 .
- the cylindrical portion 18 is preferably equipped with at least two opposing parallel flats 20 (only one visible in FIG. 1 ) formed therein/on, on which a standard spanner wrench (not shown) may engage for installing or removing cutter 14 from shank 12 , as discussed further below.
- FIGS. 2 and 3 and detail views of FIGS. 4 and 5 show details of the portions of shank 12 and cutter 14 which form the coupling mechanism between cutter 14 and shank 12 .
- the coupling mechanism includes, as part of cutter 14 : an outwardly protruding male threaded portion 22 extending opposite active fluted portion 16 ; a radial aligner portion 28 disposed concentric to the longitudinal axis A and extending between the short cylindrical portion 18 and the threaded portion 22 ; and a flat axial stop shoulder 30 which bridges the radial gap between the smaller diameter, radial aligner 28 , and the larger diameter, short cylindrical portion 18 .
- shoulder 30 may disposed perpendicular to the longitudinal axis A. In other embodiments, shoulder 30 may be slightly inclined (up to) +/ ⁇ 3° to a reference drawn perpendicular to the longitudinal axis A.
- the coupling mechanism also includes, as part of shank 12 : a generally smooth alignment bore 24 disposed concentric to longitudinal axis A, a female threaded bore 32 extending from the alignment bore 24 , and an axial stop surface 34 disposed perpendicular to the longitudinal axis A at an end of shank 12 adjacent the alignment bore 24 .
- the radial aligner portion 28 is formed generally as a portion of a truncated cone and includes an outward facing circumferential surface 29 disposed at an angle ⁇ 1 relative to longitudinal axis A.
- the angle ⁇ 1 is generally in the range of about 1° to about 7°.
- a truncated cone has been found to be preferable when the cutter 14 is coupled with steel shanks while the cylindrical shape has been found to be preferable when the cutter 14 is coupled with carbide shanks.
- the alignment bore 24 is formed in a generally corresponding shape to aligner portion 28 .
- the diameter of the aligner portion 28 may be slightly larger (preferred for steel shanks) or equal to (preferred for carbide shanks) than the diameter of the alignment bore 24 .
- alignment bore 24 is formed in a generally corresponding shape to aligner portion 28
- alignment bore 24 is also formed generally as a portion of a truncated cone and includes an inward facing circumferential surface 25 disposed at an angle ⁇ 2 relative to the longitudinal axis A.
- the angle ⁇ 2 generally is in the range of from about 0° to about 7° depending on the angle ⁇ 1 of the outward facing circumferential surface 29 .
- threaded portion 22 of cutter 14 includes a number of threads 22 a , preferably at least 4 (although other numbers may be employed), disposed at a first pitch P 1 about longitudinal axis A and threaded bore 32 includes at least a corresponding number of female threads 32 a disposed about longitudinal axis A at a second pitch P 2 , which is different than P 1 .
- the second pitch P 2 is greater than the first pitch P 1 by about 0.005 mm.
- Assembly of the modular cutting tool assembly 10 is performed by engaging the threaded portion 22 of cutter 14 with the threaded bore 32 of the shank 12 and subsequently rotating one or both of the cutter 14 and/or shank 12 until the radial aligner portion 28 of cutter 14 is seated within the alignment bore 24 of shank 12 and the axial stop shoulder 30 of the cutter 14 abuts the axial stop surface 34 of the shank 12 .
- the axial position of cutter 14 with respect to shank 12 is derived from the direct contact of stop shoulder 30 of cutter 14 with the axial stop surface 34 of shank 12 . Once stop shoulder 30 and stop surface 34 are engaged, the coupling is preferably further tightened to a specified torque using a torque limiting wrench to avoid excessive tension of the cutter 14 .
- FIG. 6 shows a detail view of another embodiment of a coupling mechanism between a shank 12 ′ (shown in cross-section) and a cutter 14 ′ of a modular cutting tool 10 ′.
- the cutting tool 10 ′ may be of similar outward appearance to cutting tool 10 , previously described, and cutter 14 ′ and shank 12 ′ interact in a similar manner as cutter 14 and shank 12 aside from the inclusion of a second radial aligner portion 40 disposed adjacent threaded portion 22 opposite radial aligner portion 28 .
- cutter 14 ′ is coupled with shank 12 ′, such as shown in FIG.
- the outward facing circumferential surface (not numbered) of the second radial aligner portion 40 engages the inward facing circumferential surface (not numbered) of a second alignment bore 42 formed in shank 12 ′ adjacent threaded bore 32 opposite first alignment bore 24 .
- radial aligner portion 40 is of generally similar, or slightly smaller diameter than the diameter of the second alignment bore 42 .
- second radial aligner portion 40 may be disposed at angles ranging from 0° to about 6° with respect to the central longitudinal axis A, while the surface (not numbered) of the second alignment bore 42 may be disposed at the same angle, or within a range of 1°-2° of the angle of the surface of the second radial aligner portion 40 .
- second radial aligner portion 40 in addition to radial aligner portion 28 , it is to be appreciated that embodiments of the present invention may include only second radial alignment portion 40 without radial alignment portion 28 .
- FIG. 7 shows an exploded side view of another example embodiment of a modular cutting tool 50 in accordance with the present invention which includes a shank 52 and a cutter 54 coupled via another coupling mechanism in accordance with the present invention.
- Shank 52 and cutter 54 may be of generally similar construction as shanks 12 , 12 ′ and cutters 14 , 14 ′ previously described and respectively include a female threaded bore 58 (including female threads 58 a , 58 b ) and a male threaded portion 60 (including male threads 60 a , 60 b ).
- a female threaded bore 58 including female threads 58 a , 58 b
- male threaded portion 60 including male threads 60 a , 60 b
- the threads 60 a , 60 b of the male threaded portion 60 are disposed at a first taper angle ⁇ C (measured with respect to a reference disposed parallel to the central longitudinal axis A) while the threads 58 a , 58 b of the female threaded bore 58 are disposed at a second taper angle ⁇ S (measured with respect to a reference disposed parallel to the central longitudinal axis A).
- FIGS. 8 through 15 show another specific embodiment of a rotary cutting tool wherein the modular rotary cutting tool comprises the basic components of a replaceable cutter member generally designated as 70 (see FIG. 13 ) and a reusable shank member generally designated as 72 (see FIG. 8 ).
- the cutter member 70 has an axial forward end 76 and an opposite axial rearward end 78 .
- the axial length of the cutter member 70 is dimension “DD”.
- the minimum diameter of the cutter member is at the axial rearward end 78 and is dimension “LL”.
- the cutter member 70 has a central longitudinal axis W-W.
- the replacebable cutter member 70 which is shown in more detail in FIGS.
- the cutter member can be, for example, without limitation, a face mill, rounded tip mill, slitting mill, drill, reamer, or any other replaceable tip for milling, drilling, reaming or other metal cutting applications, formed from carbide or other suitable material or materials may be employed without varying from the scope of the present invention.
- Shank member 72 has an elongate geometry and has an axial forward end 110 and an axial rearward end 112 .
- Shank member 72 has an axial length “RR” and a diameter “SS”.
- Shank member 72 may be formed from steel, carbide or other suitable material formed in a generally cylindrical shape. It is to be appreciated that other cross-sections, shapes, and materials for the shank member 72 may also be employed without varying from the scope of the present invention. It is also to be appreciated that shank member 72 may be formed as a generally solid member, as shown in the illustrated embodiment of FIGS. 8-12 .
- shank member 72 may contain one or more internal passages through which a flow of coolant and/or lubricant travels thereby providing coolant and/or lubricant to cutter member 70 including the vicinity of where the cutter member engages the workpiece.
- the exposed portion of the cutter member 70 is structured to perform a cutting (or material removal) operation on a workpiece (not illustrated).
- the exposed portion of the cutter member 70 comprises a fluted cutting region (see bracket 80 ), which is at the axial forward end 76 of the cutter member 70 , The maximum diameter of the fluted cutting region 80 is dimension “CC”.
- the exposed portion of the cutter member 70 further includes a short cylindrical section 82 , which is axially rearward of the fluted cutting region 80 .
- the short cylindrical section 82 has a pair of opposed flats 86 (only one visible in FIG. 13 ) formed thereon.
- the flat 86 has an axial length “II”.
- a standard spanner wrench (not shown) may engage the opposed flats 86 for installing or removing the cutter member 70 from the shank member 72 .
- FIGS. 8-15 these drawings illustrate details of the shank member 72 and cutter member 70 that includes the coupling mechanism between cutter member 70 and shank member 72 .
- the coupling mechanism includes, as part of cutter member 70 , an elongate male threaded portion (see bracket 100 in FIG. 13 ) that is adjacent to the axial rearward end 78 of the cutter member 70 .
- the male threaded portion 100 extends in an axial forward direction from the axial rearward end 78 of the cutter member 70 .
- the coupling mechanism further includes an axial forward radial aligner portion 90 that is disposed concentric to the central longitudinal axis W-W and which extends in the axial forward direction from the male threaded portion 100 .
- An arcuate fillet 96 joins the axial forward radial aligner portion 90 with a flat axial stop shoulder 94 wherein the fillet 96 and the flat axial stop shoulder 94 together bridge the radial gap between the axial forward radial aligner portion 90 , which has a smaller diameter relative to the larger diameter short cylindrical portion 82 .
- dimension EE is the axial length of the arcuate fillet 96 .
- the arcuate fillet 96 has a radius EE′ (see FIGS. 13 and 14 ).
- the ratio of the fillet ( 96 ) radius EE′ to the diameter CC of the cutter member 70 can range between about 0.02 and about 0.04 wherein a preferred EE′/CC ratio can be 0.025 and 0.035. It is critical to provide a fillet 96 with a radius EE′ that falls within the above range for the EE′/CC ratio of about 0.02 and about 0.04. By keeping the EE′/CC ratio within this range, the amount of face contact between the flat axial stop shoulder 94 and the axial stop shoulder 126 is sufficient to maintain satisfactory stiffness and accuracy and also maintain lower stresses at the point of the arcuate fillet 96 .
- Dimension FF is the axial length from the axial flat stop shoulder to the axial rear end of the axial forward radial aligner portion. It is beneficial to maintain the distance FF to be as great as practical because the greater the distance FF, the greater amount of torque is necessary to tighten the cutter member 70 to the shank member 72 . The greater the dimension FF, the less the distortion of the threads during use. It has been found that the preferred minimum ratio of the dimension FF to the diameter CC of the cutter member 70 is about 0.18. Although the FF/CC ratio can range between about 0.15 and about 0.25.
- Dimension GG is the axial length between the axial flat stop shoulder and the rear end of the cutter member.
- Dimension HH is the maximum diameter of the axial forward radial aligner portion, which is at the axial forward end thereof.
- Dimension JJ is the axial length of the flat on the short cylindrical section.
- flat axial stop shoulder 94 may be disposed perpendicular to the longitudinal axis W-W.
- flat axial stop shoulder 94 may be slightly inclined (up to +/ ⁇ 3°) to a reference drawn perpendicular to the longitudinal axis W-W. The extent or degree of the inclination can depend upon the specific application for the modular rotary cutting tool.
- the axial forward radial aligner portion 90 is formed generally as a portion of a truncated cone and includes an outward facing circumferential surface 92 disposed at an angle AA (see FIG. 13 ) relative to central longitudinal axis W-W of the cutter member 70 . While specific values of angle AA are set forth herein in Table 1, in exemplary embodiments of the present invention, the angle AA is generally in the range of about 1° to about 7°.
- axial forward radial aligner portion 90 may be of a generally cylindrical shape (i.e., AA is equal to zero degrees (0°).
- elongate male threaded portion 100 which has a maximum diameter “MM”, of cutter member 70 includes a plurality of male threads ( 102 , 104 ), preferably at least five male threads (although a greater number of male threads may be employed).
- the male threads ( 102 , 104 ) are disposed at a third pitch P 3 about longitudinal axis W-W.
- the male threads have a depth OO (see FIG. 15 ) and have side walls of adjacent threads ( 102 , 104 ) disposed at angle NN relative to each other.
- the male threaded portion 100 has an orientation such that the distal surfaces of the male threads ( 102 , 104 ) are disposed at angle BB relative to the central longitudinal axis W-W of the cutter member 70 , and the roots of the male threads ( 102 , 104 ) are disposed relative to the central longitudinal axis W-W of the cutter member 70 at the angle “QQ”.
- the maximum radial distance from the root of the axial forwardmost male thread to the centerline (CL in FIG. 15 ) of the threaded portion is dimension DD. Specific values of these dimensions are set forth in Table 1.
- the axial forwardmost male thread (see 201 A in FIG. 13 ) to have a minor diameter, which is the maximum minor diameter for the male threaded portion, that is between about 60% and about 70% of the maximum diameter (CC) of the cutter member 70 .
- a narrower range for the value of the maximum minor diameter of the male threaded portion is between about 65% and about 70% of maximum diameter (CC) of the cutter member 70 .
- the coupling mechanism also includes, as part of shank member 72 , a shank bore 114 that has a mouth at the axial forward end thereof.
- the maximum diameter of the mouth is “WW”.
- the shank bore 114 includes an axial forwardmost shank bore portion 116 , which is generally smooth, disposed concentric to longitudinal axis X-X, and has a maximum diameter “VV”.
- the axial forwardmost shank bore portion 116 has an inward facing circumferential surface 118 .
- the axial forwardmost shank bore portion 116 is disposed relative to the central longitudinal axis W-W of the cutter member 70 at an angle “TT”.
- the second axial forward shank bore portion 122 which is generally smooth, that has an inwardly facing circumferential surface 124 .
- the second axial forward shank bore portion 22 is axially rearward of the axial forwardmost shank bore portion 116 .
- the second axial forward shank bore portion 122 is disposed relative to the central longitudinal axis X-X of the shank member 72 at an angle “UU”.
- the maximum diameter of the second axial forward shank bore portion 122 is dimension “CCC”.
- the shank member 72 further has an axial stop shoulder 126 disposed perpendicular to the longitudinal axis X-X at an end of shank member 72 adjacent the forwardmost smooth alignment bore 116 .
- the axial stop shoulder 126 may be slightly inclined (up to +/ ⁇ 3°) to a reference drawn perpendicular to the longitudinal axis X-X. The extent or degree of the inclination can depend upon the specific application for the modular rotary cutting tool.
- Dimension XX is the axial length between the axial forward end of the shank member and the rear end of the axial forwardmost shank bore portion.
- Dimension YY is the axial length between the axial forward end of the shank member and the rear end of the second axial forward shank bore portion.
- the shank bore 114 further includes a female threaded bore portion 130 extending a dimension “ZZ” in an axial rearward direction from the second forward alignment bore 122 .
- the female threaded bore portion 130 includes a number of female threads ( 132 , 134 ) corresponding to the number of male threads ( 102 , 104 ) and the female threads ( 132 , 134 ) disposed about longitudinal axis X-X at a fourth pitch P 4 , which is different than the third pitch P 3 .
- Specific values of the fourth pitch P 4 are set forth in Table 1 herein.
- Dimension EEE is angle at which the opposed surfaces of adjacent female threads are disposed relative to each other
- dimension FFF is the depth of the female threads.
- Dimension GGG is the angle at which the roots of the female threads are disposed relative to the central longitudinal axis X-X of the shank member.
- Dimension III is the starting radius of the female threaded portion.
- the axial forwardmost shank bore portion 116 is formed in a generally corresponding shape to forward radial aligner portion 90 of the cutter member 70 .
- the diameter of the forward radial aligner portion 90 is slightly larger than the diameter of the axial forwardmost shank bore portion 116 . This difference in dimension between the diameters of the forward radial aligner portion 90 and the axial forwardmost shank bore portion 116 provides an interference fit between the cutter member 70 and the shank member 72 .
- the extent of this interference fit i.e., difference in diameters of the forward radial aligner portion 90 and the axial forwardmost shank bore portion 116
- the “stand off” can range between about 0.015 and about 0.035 of the maximum diameter (CC) of the cutter member 70 with one preferable value of the “stand off” being equal to about 0.025 the maximum diameter (CC) of the cutter member 70 .
- the “stand off” will close when the tool tightens due to the elastic deformation of the shank member.
- the dimensional relationship between the diameter of the forward radial aligner portion 90 and the diameter of the axial forwardmost shank bore portion 116 may vary depending upon the specific application for the rotary cutting tool.
- the shank bore 114 further contains an axial rearward shank bore portion 140 that has an axial length “AAA” and a diameter “BBB”.
- the axial rearward shank bore portion 140 has a rearward shank bore wall 144 .
- the axial rearward shank bore portion 140 has a maximum diameter BBB.
- the shank bore 114 terminates at a terminal end 146 .
- the fourth pitch P 4 is greater than the third pitch P 3 .
- the resulting stress on male threaded portion 100 of cutter member 70 when coupled with shank member 72 is dispersed more evenly among the male threads ( 102 , 104 ) as compared to an embodiment in which cooperating threads of generally the same pitch are utilized.
- thread pitches varying from about 0.002 mm to about 0.010 mm between the respective threads of the shank member 72 and cutter member 70 have been employed.
- one preferable difference in the pitch between the male threads and the female threads in the range of 0.003 mm and 0.005 mm (i.e., 3 to 5 microns).
- the difference resides in the pitch of the female threads being greater than the pitch of the male threads.
- the pitch of the male threads is equal to 1.755 mm and the pitch of the female threads in the corresponding shank bore of the shank member is equal to 1.760 mm.
- the pitch of the male threads is equal to 2.345 mm and the pitch of the female threads in the corresponding shank bore of the shank member is equal to 2.35 mm.
- stress is generally concentrated at the thread closest to flat axial stop shoulder due to the general inelasticity of the carbide or steel cutter.
- Assembly of the modular cutting tool assembly is performed by engaging the male threaded portion 100 of cutter member 70 with the female threaded bore 130 of the shank member 72 and subsequently rotating one or both of the cutter member 70 and/or shank member 72 until the forward radial aligner portion 90 of cutter member 70 is seated within the axial forwardmost shank bore portion 116 of shank member 72 and the axial stop shoulder 94 of the cutter member 70 abuts the axial stop shoulder 126 of the shank member 72 .
- the axial position of cutter member 70 with respect to shank member 72 is derived from the direct contact of stop shoulder 94 of cutter member 70 with the axial stop surface 126 of shank member 72 .
- the coupling is preferably further tightened to a specified torque using a torque limiting wrench to avoid excessive tension of the cutter member 70 .
- the rear end 70 of the cutter member 70 is spaced apart from the terminal end 146 of the shank bore 114 .
- the Table 1 sets forth the dimensional relationships of certain structural features of specific embodiments wherein one specific embodiment has a cutting diameter equal to 12 mm and the other specific embodiment has a cutting diameter equal to 16 mm.
- the length dimensions are set forth as a ratio of the specific dimension to the maximum diameter of the fluted cutter portion of the cutter member taken at the axial forward end of the cutter member, which is dimension CC in Table 1.
- the angular dimensions are set forth as angles.
- FIGS. 16 , 17 and 18 Exemplary competitive cutter members are shown in FIGS. 16 , 17 and 18 .
- FIG. 16 is cutter made by Sandvik.
- FIG. 17 is a cutter member made by Iscar.
- FIG. 18 is a cutter member made by Fraiza. It is apparent that these competitors' cutter members have a different geometry than the specific embodiment herein.
- FIG. 19 is graph based upon results from a computer simulation showing the maximum principle stress (MPa) under preload at each of five different threads of four different cutter members wherein thread 1 is the thread closest to the cutting region of the cutter member and thread 5 is closest to the rear end (or tail) of the cutter member.
- the cutter member represented by the hollow circle and designated in the legend as “same pitch” has five threads and the pitch of the female threads of the shank member is equal to the pitch of the male threads of the cutter member.
- the cutter assembly represented by the solid square and designated in the legend as “1 micron” has five threads and the pitch of the female threads is 1 micron greater than the pitch of the male threads.
- the cutter assembly represented by the solid triangle and designated in the legend as “2 microns” has five threads and the pitch of the female threads is 2 microns greater than the pitch of the male threads.
- the cutter member represented by the solid circle and designated in the legend as “3 microns” has five threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads.
- the threads 1 through 5 designate the threads of the cutter member wherein thread 1 is the thread closest to the cutting region and thread 5 is closest to the rear end (or tail) of the cutter member.
- the lower maximum principle stress values at thread Tare for the cutter members in which the pitch of the female threads is greater than the male threads i.e., a difference of 2 microns and 3 microns.
- the maximum principle stress at thread 1 is higher for the cutter member in which the pitch of the female threads is 1 micron greater than the pitch of the male threads.
- the maximum pirnciple stress is greatest for the cutter member in which the pitch of the female threads is the same as the pitch for the male threads.
- Lower maximum principle stress values are preferred and especially at thread 1 which is the location most susceptible to breakage. There is not as great a concern about the maximum principle stress value at thread 5 .
- FIG. 20 is graph based upon results from a computer simulation showing the maximum principle stress (MPa) under preload and bending at each of five different threads, if applicable, of six different cutter members as described below wherein thread 1 is the thread closest to the cutting region of the cutter member and thread 5 is closest to the rear end (or tail) of the cutter member.
- MPa maximum principle stress
- each cutter assembly has a different number of threads and a different pitch condition, i.e., the difference in pitch between the female threads of the shank member and the male threads of the cutter member.
- the solid circle (designated as “5 threads, 3 microns”) represents a cutter member with five threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads.
- the solid square (designated as “4 threads, 3 microns”) represents a cutter member with four threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads.
- the solid triangle (designated as “3 threads, 3 microns”) represents a cutter member with three threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads.
- the open circle (designated as “5 same pitch”) represents a cutter member with five threads and the pitch of the female threads is the same as the pitch of the male threads.
- the open square (designated as “4 same pitch”) represents a cutter member with four threads and the pitch of the female threads is the same as the pitch of the male threads.
- the open triangle (designated as “3 same pitch”) represents a cutter member with three threads and the pitch of the female threads is the same as the pitch of the male threads.
- the lower maximum principle stress values at thread 1 are for the cutter members in which the pitch of the female threads is greater than the pitch of the male threads, i.e., a difference of 3 microns.
- the maximum pirnciple stress is greatest for the cutter member in which the pitch of the female threads is the same as the pitch for the male threads.
- Lower maximum principle stress values are preferred and especially at thread 1 which is the location most susceptible to breakage. There is not as great a concern about the maximum principle stress value at thread 5 .
- the shank is provided with a threaded bore for engaging a complementary male thread on the cutter, the reverse is also possible whereby the shank is provided with a protruding male threaded portion, and the cutter is provided with an internally threaded bore.
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Abstract
A rotary cutting tool including a cutter member having an axial forward end and an axial rearward end. A cutting region is at the axial forward end of the cutter member, and a male threaded portion is adjacent the axial rearward end of the cutter member. A shank member has an axial forward end and a shank bore opening at the axial forward end. The shank bore has an axial shank bore length. The shank bore contains a female threaded portion and an axial rearward shank bore portion axially rearward of the female threaded portion. The axial rearward shank bore portion has a terminal end. When the male threaded portion of the cutter member fully engages the female threaded portion of the shank member, the axial rearward end of the cutter member being spaced a first distance axially forward of the terminal end of the axial rearward shank bore portion.
Description
- This patent application is a continuation-in-part of pending U.S. patent application Ser. No. 13/950,407 filed on Jul. 25, 2013 for a COUPLING MECHANISM FOR CUTTING TOOL to Ruy Frota De Souza et al. wherein applicants claim the benefit under the United States Patent Statute including 35 USC 120 of such pending U.S. patent application Ser. No. 13/950,407 filed on Jul. 25, 2013. Further, applicants hereby incorporate by reference herein the entirety of such pending U.S. patent application Ser. No. 13/950,407 filed on Jul. 25, 2013 for a COUPLING MECHANISM FOR CUTTING TOOL.
- 1. Field of the Invention
- The present invention relates to coupling mechanisms for use with rotary cutting tools and, more particularly, to rotary cutting tools including such coupling mechanisms.
- 2. Background Information
- Historically, end mills for metal cutting machinery were produced as a single unit, comprising a fluted cutting portion and a cylindrical or conical shank portion sized to fit a machine spindle. However, increasing global pricing of modern tool alloys along with recently developed intricate surface treatments have made such single units less economical, as the expensive shank material is generally wasted. It has therefore became common practice to produce a separate cutter made of high quality alloy or sintered carbide, which is then concentrically attached to the end of a reusable steel shank.
- It is highly desirable that the cutter be easily replaced, upon wear, while leaving the shank in the machine spindle, such that no further adjustments are required after cutter replacement. A major requirement related to such accurate milling applications is that each replacement cutter be repeatedly, accurately, centered to the true spindle axis of rotation and axially positioned correctly.
- One basic method currently in use for joining the cutter to the shank is disclosed for example in U.S. Pat. No. 5,114,286, which teaches an interchangeable cutting tool alignment and positioning system comprising a first tool segment having a male coupler and a second tool segment having a female coupler. The male coupler comprises a pilot in the form of first cylindrical mating surface, a concentric aligner in the form of second cylindrical mating surface spaced apart from the pilot, a male thread extending between the pilot and the concentric aligner and an axial stop in the form of planar surface. The female coupler comprises a pilot bore in the form of complementary cylindrical mating surface, corresponding to the cylindrical mating surface of the pilot, a concentric bore in the form of a complementary cylindrical mating surface corresponding to the cylindrical mating surface of the concentric aligner, a female thread extending between the pilot bore and the concentric bore, and an axial stop in the form of complementary planar surface.
- The described pilot, concentric aligner, pilot bore and concentric bore, are necessary because the threaded coupler by its own is not sufficiently accurate for such repeated replacement of cutters.
- Further improvements to the above basic concept are also known. For instance, U.S. Pat. No. 6,485,220 discloses a frustoconical radial alignment instead of a cylindrical alignment, as well as a strengthened thread root and U.S. Pat. No. 7,329,073 describes adjacent axial and radial stop surfaces.
- Nevertheless all the above described solutions suffer from restrictive production requirements. Typical production tolerances of the cylindrical mating surfaces on the cutter and shank, sufficient for satisfying the need of replaceable cutters falling repeatedly in the desired range of concentricity and axis position, are less than 5 micrometers. Such close tolerances necessitate an additional grinding process.
- Furthermore, sintered carbide cutters by their nature are very hard yet also very brittle. Direct coupling of the hard cutter to the steel shank imposes stresses on the coupling where the two different materials engage. More particularly, in cases where a carbide cutter is threaded into a steel shank, failure of the connection is likely to occur at or near the base of the threaded portion of the carbide cutter, which commonly also damages the steel shank, rendering it unsuitable for reuse.
- Hence there is room for improvement in coupling mechanisms for use with rotary cutting tools and also to rotary cutting tools including such coupling mechanisms.
- As one aspect of the present invention a rotary cutting tool is provided. The rotary cutting tool comprises a cutter of generally cylindrical shape disposed about a central longitudinal axis. The cutter includes a first end having an active fluted portion and an opposite second end, the second end having a male threaded portion disposed thereabout. The rotary cutting tool further comprises a shank of generally cylindrical shape disposed about the central longitudinal axis, the shank having a recessed female threaded portion formed in a first end. The male threaded portion includes a number of threads disposed at a first pitch and the female threaded portion includes a number of threads disposed at a second pitch different than the first pitch. The cutter and the shank are selectively coupled via threaded engagement of the male threaded portion and the female threaded portion.
- The first pitch may be less than the second pitch.
- The first pitch may be about 0.005 mm less than the second pitch.
- The difference between the first pitch and the second pitch may be in the range of about 0.002 to about 0.010 mm.
- The cutter may be formed from a carbide material and the shank may be formed from a tool steel.
- The cutter may comprise an outward facing circumferential surface extending a distance along the central longitudinal axis disposed between the active fluted portion and the male threaded portion, the shank may comprise an inward facing circumferential surface extending a distance along the central longitudinal axis between the female threaded portion and the first end of the shank, and the outward facing circumferential surface may be disposed adjacent to, and facing the inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged.
- The outward facing circumferential surface may be generally in the form of a portion of a truncated cone disposed at a first angle with respect to the central longitudinal axis and the inward facing circumferential surface may be generally in the form of a portion of a truncated cone disposed at a second angle with respect to the central longitudinal axis.
- The first angle may be in the range of about 1° to about 7°.
- The second angle may be in the range of about 1° to about 7°.
- The outward facing circumferential surface may be generally a cylindrical surface disposed parallel to the central longitudinal axis and the inward facing circumferential surface may be generally a cylindrical surface disposed parallel to the central longitudinal axis.
- The cutter may comprise an outward facing circumferential surface extending a distance along the central longitudinal axis disposed adjacent the male threaded portion and opposite the active fluted portion, the shank may comprise an inward facing circumferential surface extending a distance along the central longitudinal axis adjacent the female threaded portion opposite the first end of the shank, and the outward facing circumferential surface may be disposed adjacent to, and facing the inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged.
- The outward facing circumferential surface may be disposed at an angle in the range of 0° to about 6° with respect to the central longitudinal axis.
- The inward facing circumferential surface may be disposed within the range of 0° to 2° of the angle of the outward facing circumferential surface.
- The cutter may comprise a first outward facing circumferential surface extending a distance along the central longitudinal axis disposed between the active fluted portion and the male threaded portion and a second outward facing circumferential surface extending a distance along the central longitudinal axis adjacent the male threaded portion and opposite the active fluted portion, the shank may comprise a first inward facing circumferential surface extending a distance along the central longitudinal axis between the female threaded portion and the first end of the shank and a second inward facing circumferential surface extending a distance along the central longitudinal axis adjacent the female threaded portion opposite the first end of the shank, the first outward facing circumferential surface may disposed adjacent to, and facing the first inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged, and the second outward facing circumferential surface may be disposed adjacent to, and facing the second inward facing circumferential surface when the male threaded portion and the female threaded portion are threadedly engaged.
- As another aspect of the present invention, a rotary cutting tool is provided. The rotary cutting tool comprises: a cutter of generally cylindrical shape disposed about a central longitudinal axis, the cutter having a first end having an active fluted portion and an opposite second end, the second end having a male threaded portion disposed thereabout; and a shank of generally cylindrical shape disposed about the central longitudinal axis, the shank having a recessed female threaded portion formed in a first end. The male threaded portion includes a number of threads disposed at a first pitch and at a first taper angle, the female threaded portion includes a number of threads disposed at a second pitch and at a second taper angle different than the first taper angle, and the cutter and the shank are selectively coupled via threaded engagement of the male threaded portion and the female threaded portion.
- The first taper angle may be less than the second taper angle.
- The first pitch may be equal to the second pitch or the first pitch may be less than the second pitch.
- Concepts of the present invention will now be described in connection with certain non-limiting embodiments with reference to the following illustrative figures so that it may be more fully understood.
- With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purpose of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
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FIG. 1 shows an isometric view of an example embodiment of a modular rotary cutting tool in accordance with the present invention. -
FIG. 1B shows a side view of the modular cutting tool ofFIG. 1 with the shank portion shown in cross-section. -
FIG. 2 shows an exploded isometric view of the modular cutting tool ofFIG. 1 . -
FIG. 3 shows an exploded side view of the modular cutting tool ofFIG. 1 with the shank portion shown in cross-section to show internal details. -
FIG. 4 shows a detail side view of the cutter portion of the rotary cutting tool ofFIG. 1 . -
FIG. 5 shows a detail cross-sectional view of a portion of the shank portion of the rotary cutting tool ofFIG. 1 . -
FIG. 6 shows a side view of another example embodiment of a coupling mechanism in accordance the present invention shown partially in cross-section to show internal details. -
FIG. 7 shows an exploded side view of another example embodiment of a modular cutting tool in accordance with the present invention with the shank portion shown in cross-section to show internal details. -
FIG. 8 is a side view of the shank portion of another specific embodiment of a rotary cutting tool. -
FIG. 9 shows a cross-sectional view of the shank portion ofFIG. 8 taken along section line 9-9 ofFIG. 8 . -
FIG. 10 is an enlarged view of a portion of the shank portion ofFIG. 9 encompassed by the circle designated as 10 inFIG. 9 . -
FIG. 11 is an enlarged view of the portion of the shank portion ofFIG. 10 encompassed by the circle designated as 11 inFIG. 10 . -
FIG. 12 is an enlarged view of the portion of the shank portion ofFIG. 10 encompassed by the circle designated as 12 inFIG. 10 . -
FIG. 13 is a side view of the replaceable cutter member. -
FIG. 14 is a cross-sectional view of the replaceable cutter member taken along section line 14-14 ofFIG. 13 . -
FIG. 15 is an enlarged view of the replaceable cutter member encompassed by the circle designated as 1 inFIG. 14 . -
FIG. 16 is photograph of a competitive cutter member made by Sandvik. -
FIG. 17 is photograph of a competitive cutter member made by Iscar. -
FIG. 18 is photograph of a competitive cutter member made by Fraiza. -
FIG. 19 is graph showing results of a computer simulation wherein the maximum principle stress (MPa) under preload at each of five different threads of four different cutter members as described in more detail hereinafter whereinthread 1 is the thread closest to the cutting region of the cutter member andthread 5 is closest to the rear end (or tail) of the cutter member. -
FIG. 20 is graph showing results of a computer simulation wherein the maximum principle stress (MPa) under preload and bending at each of five different threads, if applicable, of six different cutter members as described in more detail hereinafter whereinthread 1 is the thread closest to the cutting region of the cutter member andthread 5 is closest to the rear end (or tail) of the cutter member. - In the figures, equivalent parts are provided with the same reference signs.
- As used herein, the term “number” shall refer to any non-zero quantity (i.e., one or any quantity greater than one).
- As used herein, the term “selectively coupled” shall mean that two or more components are coupled or joined together in a manner which may be selectively undone (i.e., uncoupled) without damaging either of the components.
- As used herein, the term “pitch” shall refer to the distance measured parallel to a central axis of a threaded member between corresponding points on adjacent thread forms in the same axial plane and on the same side of the axis.
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FIGS. 1-5 show a modularrotary cutting tool 10 according to a first example embodiment of the invention disposed about a central longitudinal axisA. Cutting tool 10 includes areusable shank 12 and areplaceable cutter 14, selectively coupled together by a coupling mechanism (not numbered) formed from cooperating portions of each ofshank 12 andcutter 14 which are discussed in detail below. In the example embodiment shown inFIGS. 1-5 ,cutter 14 is in the form of an end mill formed from a carbide material, however, it is to be appreciated that another rotary cutting tool, e.g., without limitation, a face mill, rounded tip mill, slitting mill, drill, reamer, or any other replaceable tip for milling, drilling, reaming or other metal cutting applications, formed from carbide or other suitable material or materials may be employed without varying from the scope of the present invention.Shank 12 may be formed from steel, carbide or other suitable material formed in a generally cylindrical shape with a slightly stepped portion, however, it is to be appreciated that other cross-sections, shapes, and materials may also be employed without varying from the scope of the present invention. It is also to be appreciated thatshank 12 may be formed as a generally solid member, as shown in the illustrated embodiment ofFIG. 1-5 , or may include one or more internal passages through which a flow of coolant and/or lubricant may be provided tocutter 14. - Continuing to refer to
FIG. 1 , the exposed portion of the cutter 14 (when installed in shank 12) may include an activefluted portion 16 structured to perform cutting operations on a workpiece (not shown), followed by a shortcylindrical portion 18. Thecylindrical portion 18 is preferably equipped with at least two opposing parallel flats 20 (only one visible inFIG. 1 ) formed therein/on, on which a standard spanner wrench (not shown) may engage for installing or removingcutter 14 fromshank 12, as discussed further below. - The exploded views of
FIGS. 2 and 3 and detail views ofFIGS. 4 and 5 show details of the portions ofshank 12 andcutter 14 which form the coupling mechanism betweencutter 14 andshank 12. More particularly, the coupling mechanism includes, as part of cutter 14: an outwardly protruding male threadedportion 22 extending opposite activefluted portion 16; aradial aligner portion 28 disposed concentric to the longitudinal axis A and extending between the shortcylindrical portion 18 and the threadedportion 22; and a flataxial stop shoulder 30 which bridges the radial gap between the smaller diameter,radial aligner 28, and the larger diameter, shortcylindrical portion 18. As shown in the illustrated example embodiment,shoulder 30 may disposed perpendicular to the longitudinal axis A. In other embodiments,shoulder 30 may be slightly inclined (up to) +/−3° to a reference drawn perpendicular to the longitudinal axis A. - The coupling mechanism also includes, as part of shank 12: a generally smooth alignment bore 24 disposed concentric to longitudinal axis A, a female threaded bore 32 extending from the alignment bore 24, and an
axial stop surface 34 disposed perpendicular to the longitudinal axis A at an end ofshank 12 adjacent the alignment bore 24. - Referring to the detail view of
cutter 14 shown inFIG. 4 , theradial aligner portion 28 is formed generally as a portion of a truncated cone and includes an outward facingcircumferential surface 29 disposed at an angle δ1 relative to longitudinal axis A. In example embodiments of the present invention, the angle δ1 is generally in the range of about 1° to about 7°. Alternatively,radial aligner portion 28 may be of generally cylindrical shape (i.e., δ1=0 degrees). In general, a truncated cone has been found to be preferable when thecutter 14 is coupled with steel shanks while the cylindrical shape has been found to be preferable when thecutter 14 is coupled with carbide shanks. - Referring to the cross-sectional detail view of an end portion of
shank 12 shown inFIG. 5 , the alignment bore 24 is formed in a generally corresponding shape to alignerportion 28. In general, the diameter of thealigner portion 28 may be slightly larger (preferred for steel shanks) or equal to (preferred for carbide shanks) than the diameter of the alignment bore 24. - As the alignment bore 24 is formed in a generally corresponding shape to aligner
portion 28, in the illustrated embodiment alignment bore 24 is also formed generally as a portion of a truncated cone and includes an inward facingcircumferential surface 25 disposed at an angle δ2 relative to the longitudinal axis A. As the inward facingcircumferential surface 25 ofshank 12 generally cooperates with the outward facingcircumferential surface 29 ofcutter 14, in example embodiments of the present invention, the angle δ2 generally is in the range of from about 0° to about 7° depending on the angle δ1 of the outward facingcircumferential surface 29. - Referring to
FIGS. 4 and 5 , threadedportion 22 ofcutter 14 includes a number ofthreads 22 a, preferably at least 4 (although other numbers may be employed), disposed at a first pitch P1 about longitudinal axis A and threaded bore 32 includes at least a corresponding number offemale threads 32 a disposed about longitudinal axis A at a second pitch P2, which is different than P1. In the example embodiment shown inFIGS. 1-5 , the second pitch P2 is greater than the first pitch P1 by about 0.005 mm. By utilizing a larger pitch P2 in the threaded bore 34 of theshank 12, and thus a smaller pitch P1 incutter 14, the resulting stress on threadedportion 22 ofcutter 14 when coupled withshank 12 is dispersed more evenly among thethreads 22 a as compared to an embodiment in which cooperating threads of generally the same pitch are utilized. In example embodiments of the present invention, thread pitches varying from about 0.002-0.010 mm between the respective threads of theshank 12 andcutter 14 have been employed. In contrast to embodiments of the present invention, in instances where cooperating threads of generally the same pitch are utilized stress is generally concentrated at the thread closest toaxial stop shoulder 30 due to the general inelasticity of the carbide orsteel cutter 14. By more evenly distributing the stress among thethreads 22 a of threadedportion 22, embodiments of the present invention allow for higher loads to be applied to the connection before failure. - Assembly of the modular
cutting tool assembly 10 is performed by engaging the threadedportion 22 ofcutter 14 with the threaded bore 32 of theshank 12 and subsequently rotating one or both of thecutter 14 and/orshank 12 until theradial aligner portion 28 ofcutter 14 is seated within the alignment bore 24 ofshank 12 and theaxial stop shoulder 30 of thecutter 14 abuts theaxial stop surface 34 of theshank 12. The axial position ofcutter 14 with respect toshank 12 is derived from the direct contact ofstop shoulder 30 ofcutter 14 with theaxial stop surface 34 ofshank 12. Oncestop shoulder 30 and stopsurface 34 are engaged, the coupling is preferably further tightened to a specified torque using a torque limiting wrench to avoid excessive tension of thecutter 14. -
FIG. 6 shows a detail view of another embodiment of a coupling mechanism between ashank 12′ (shown in cross-section) and acutter 14′ of amodular cutting tool 10′. The cuttingtool 10′ may be of similar outward appearance to cuttingtool 10, previously described, andcutter 14′ andshank 12′ interact in a similar manner ascutter 14 andshank 12 aside from the inclusion of a secondradial aligner portion 40 disposed adjacent threadedportion 22 oppositeradial aligner portion 28. Whencutter 14′ is coupled withshank 12′, such as shown inFIG. 6 , the outward facing circumferential surface (not numbered) of the secondradial aligner portion 40 engages the inward facing circumferential surface (not numbered) of a second alignment bore 42 formed inshank 12′ adjacent threaded bore 32 opposite first alignment bore 24. In example embodiments of the present invention,radial aligner portion 40 is of generally similar, or slightly smaller diameter than the diameter of the second alignment bore 42. Also, the surface (not numbered) of secondradial aligner portion 40 may be disposed at angles ranging from 0° to about 6° with respect to the central longitudinal axis A, while the surface (not numbered) of the second alignment bore 42 may be disposed at the same angle, or within a range of 1°-2° of the angle of the surface of the secondradial aligner portion 40. Although shown having secondradial aligner portion 40 in addition toradial aligner portion 28, it is to be appreciated that embodiments of the present invention may include only secondradial alignment portion 40 withoutradial alignment portion 28. -
FIG. 7 shows an exploded side view of another example embodiment of amodular cutting tool 50 in accordance with the present invention which includes ashank 52 and acutter 54 coupled via another coupling mechanism in accordance with the present invention.Shank 52 andcutter 54 may be of generally similar construction asshanks cutters female threads male threads FIG. 7 accomplishes a similar result by orienting the male and female threaded portions at different angles with respect to each other. For example, in the embodiment illustrated inFIG. 7 , thethreads portion 60 are disposed at a first taper angle αC (measured with respect to a reference disposed parallel to the central longitudinal axis A) while thethreads female threads male threads portions 58, 60 similar to that created by the use of different thread pitches as previously discussed is created even when the thread pitches PS and PC are the same. It is to be appreciated that such embodiment could also be utilized with different thread pitches PS and PC as an alternative to being used with portions having the same pitch. -
FIGS. 8 through 15 show another specific embodiment of a rotary cutting tool wherein the modular rotary cutting tool comprises the basic components of a replaceable cutter member generally designated as 70 (seeFIG. 13 ) and a reusable shank member generally designated as 72 (seeFIG. 8 ). Thecutter member 70 has an axialforward end 76 and an opposite axialrearward end 78. The axial length of thecutter member 70 is dimension “DD”. The minimum diameter of the cutter member is at the axialrearward end 78 and is dimension “LL”. Thecutter member 70 has a central longitudinal axis W-W. In the specific embodiment illustrated inFIGS. 8 through 15 , thereplacebable cutter member 70, which is shown in more detail inFIGS. 13-15 , is in the form of fluted cutter formed from a carbide material, however, it is to be appreciated that the cutter member can be, for example, without limitation, a face mill, rounded tip mill, slitting mill, drill, reamer, or any other replaceable tip for milling, drilling, reaming or other metal cutting applications, formed from carbide or other suitable material or materials may be employed without varying from the scope of the present invention. -
Shank member 72 has an elongate geometry and has an axialforward end 110 and an axialrearward end 112.Shank member 72 has an axial length “RR” and a diameter “SS”.Shank member 72 may be formed from steel, carbide or other suitable material formed in a generally cylindrical shape. It is to be appreciated that other cross-sections, shapes, and materials for theshank member 72 may also be employed without varying from the scope of the present invention. It is also to be appreciated thatshank member 72 may be formed as a generally solid member, as shown in the illustrated embodiment ofFIGS. 8-12 . As an alternative, theshank member 72 may contain one or more internal passages through which a flow of coolant and/or lubricant travels thereby providing coolant and/or lubricant tocutter member 70 including the vicinity of where the cutter member engages the workpiece. - When the
cutter member 70 is installed in (or threadedly connected to) theshank member 72, a portion of thecutter member 70 is exposed outside of theshank member 72. The exposed portion of thecutter member 70 is structured to perform a cutting (or material removal) operation on a workpiece (not illustrated). In the specific embodiment, the exposed portion of thecutter member 70 comprises a fluted cutting region (see bracket 80), which is at the axialforward end 76 of thecutter member 70, The maximum diameter of the fluted cuttingregion 80 is dimension “CC”. The exposed portion of thecutter member 70 further includes a shortcylindrical section 82, which is axially rearward of the fluted cuttingregion 80. The shortcylindrical section 82 has a pair of opposed flats 86 (only one visible inFIG. 13 ) formed thereon. The flat 86 has an axial length “II”. A standard spanner wrench (not shown) may engage theopposed flats 86 for installing or removing thecutter member 70 from theshank member 72. - Referring to
FIGS. 8-15 , these drawings illustrate details of theshank member 72 andcutter member 70 that includes the coupling mechanism betweencutter member 70 andshank member 72. More particularly, as shown inFIGS. 13-15 , the coupling mechanism includes, as part ofcutter member 70, an elongate male threaded portion (seebracket 100 inFIG. 13 ) that is adjacent to the axialrearward end 78 of thecutter member 70. The male threadedportion 100 extends in an axial forward direction from the axialrearward end 78 of thecutter member 70. - The coupling mechanism further includes an axial forward
radial aligner portion 90 that is disposed concentric to the central longitudinal axis W-W and which extends in the axial forward direction from the male threadedportion 100. Anarcuate fillet 96 joins the axial forwardradial aligner portion 90 with a flataxial stop shoulder 94 wherein thefillet 96 and the flataxial stop shoulder 94 together bridge the radial gap between the axial forwardradial aligner portion 90, which has a smaller diameter relative to the larger diameter shortcylindrical portion 82. As shown in the drawings, dimension EE is the axial length of thearcuate fillet 96. - The
arcuate fillet 96 has a radius EE′ (seeFIGS. 13 and 14 ). The ratio of the fillet (96) radius EE′ to the diameter CC of thecutter member 70 can range between about 0.02 and about 0.04 wherein a preferred EE′/CC ratio can be 0.025 and 0.035. It is critical to provide afillet 96 with a radius EE′ that falls within the above range for the EE′/CC ratio of about 0.02 and about 0.04. By keeping the EE′/CC ratio within this range, the amount of face contact between the flataxial stop shoulder 94 and theaxial stop shoulder 126 is sufficient to maintain satisfactory stiffness and accuracy and also maintain lower stresses at the point of thearcuate fillet 96. In other words, keeping the EE′/CC ratio within this range balances the amount of face contact (between the flataxial stop shoulder 94 and the axial stop shoulder 126) and the size of the radius EE′ of thearcuate fillet 96 to reduce stress at the location of thefillet 96. - Dimension FF is the axial length from the axial flat stop shoulder to the axial rear end of the axial forward radial aligner portion. It is beneficial to maintain the distance FF to be as great as practical because the greater the distance FF, the greater amount of torque is necessary to tighten the
cutter member 70 to theshank member 72. The greater the dimension FF, the less the distortion of the threads during use. It has been found that the preferred minimum ratio of the dimension FF to the diameter CC of thecutter member 70 is about 0.18. Although the FF/CC ratio can range between about 0.15 and about 0.25. Dimension GG is the axial length between the axial flat stop shoulder and the rear end of the cutter member. Dimension HH is the maximum diameter of the axial forward radial aligner portion, which is at the axial forward end thereof. Dimension JJ is the axial length of the flat on the short cylindrical section. - As shown in
FIG. 13 , flataxial stop shoulder 94 may be disposed perpendicular to the longitudinal axis W-W. In other embodiments, flataxial stop shoulder 94 may be slightly inclined (up to +/−3°) to a reference drawn perpendicular to the longitudinal axis W-W. The extent or degree of the inclination can depend upon the specific application for the modular rotary cutting tool. - Referring to
FIG. 13 , the axial forwardradial aligner portion 90 is formed generally as a portion of a truncated cone and includes an outward facingcircumferential surface 92 disposed at an angle AA (seeFIG. 13 ) relative to central longitudinal axis W-W of thecutter member 70. While specific values of angle AA are set forth herein in Table 1, in exemplary embodiments of the present invention, the angle AA is generally in the range of about 1° to about 7°. Alternatively, axial forwardradial aligner portion 90 may be of a generally cylindrical shape (i.e., AA is equal to zero degrees (0°). In general, a truncated cone has been found to be preferable when thecutter member 70 is coupled with steel shanks while the cylindrical shape has been found to be preferable when thecutter member 70 is coupled with carbide shanks. There should be an appreciation that this preference may not always be applicable in certain specific applications. - Referring to
FIGS. 13-15 , elongate male threadedportion 100, which has a maximum diameter “MM”, ofcutter member 70 includes a plurality of male threads (102, 104), preferably at least five male threads (although a greater number of male threads may be employed). The male threads (102, 104) are disposed at a third pitch P3 about longitudinal axis W-W. As shown inFIGS. 13-15 , the male threads have a depth OO (seeFIG. 15 ) and have side walls of adjacent threads (102, 104) disposed at angle NN relative to each other. The male threadedportion 100 has an orientation such that the distal surfaces of the male threads (102, 104) are disposed at angle BB relative to the central longitudinal axis W-W of thecutter member 70, and the roots of the male threads (102, 104) are disposed relative to the central longitudinal axis W-W of thecutter member 70 at the angle “QQ”. The maximum radial distance from the root of the axial forwardmost male thread to the centerline (CL inFIG. 15 ) of the threaded portion is dimension DD. Specific values of these dimensions are set forth in Table 1. - It is advantageous to provide for the axial forwardmost male thread (see 201A in
FIG. 13 ) to have a minor diameter, which is the maximum minor diameter for the male threaded portion, that is between about 60% and about 70% of the maximum diameter (CC) of thecutter member 70. A narrower range for the value of the maximum minor diameter of the male threaded portion is between about 65% and about 70% of maximum diameter (CC) of thecutter member 70. - The coupling mechanism also includes, as part of
shank member 72, ashank bore 114 that has a mouth at the axial forward end thereof. The maximum diameter of the mouth is “WW”. The shank bore 114 includes an axial forwardmost shank boreportion 116, which is generally smooth, disposed concentric to longitudinal axis X-X, and has a maximum diameter “VV”. The axial forwardmost shank boreportion 116 has an inward facingcircumferential surface 118. The axial forwardmost shank boreportion 116 is disposed relative to the central longitudinal axis W-W of thecutter member 70 at an angle “TT”. - There is a second axial forward shank bore
portion 122, which is generally smooth, that has an inwardly facingcircumferential surface 124. The second axial forward shank boreportion 22 is axially rearward of the axial forwardmost shank boreportion 116. The second axial forward shank boreportion 122 is disposed relative to the central longitudinal axis X-X of theshank member 72 at an angle “UU”. The maximum diameter of the second axial forward shank boreportion 122 is dimension “CCC”. Theshank member 72 further has anaxial stop shoulder 126 disposed perpendicular to the longitudinal axis X-X at an end ofshank member 72 adjacent the forwardmostsmooth alignment bore 116. In other specific embodiments, theaxial stop shoulder 126 may be slightly inclined (up to +/−3°) to a reference drawn perpendicular to the longitudinal axis X-X. The extent or degree of the inclination can depend upon the specific application for the modular rotary cutting tool. Dimension XX is the axial length between the axial forward end of the shank member and the rear end of the axial forwardmost shank bore portion. Dimension YY is the axial length between the axial forward end of the shank member and the rear end of the second axial forward shank bore portion. - The shank bore 114 further includes a female threaded
bore portion 130 extending a dimension “ZZ” in an axial rearward direction from the second forward alignment bore 122. The female threadedbore portion 130 includes a number of female threads (132, 134) corresponding to the number of male threads (102, 104) and the female threads (132, 134) disposed about longitudinal axis X-X at a fourth pitch P4, which is different than the third pitch P3. Specific values of the fourth pitch P4 are set forth in Table 1 herein. Dimension EEE is angle at which the opposed surfaces of adjacent female threads are disposed relative to each other, and dimension FFF is the depth of the female threads. Dimension GGG is the angle at which the roots of the female threads are disposed relative to the central longitudinal axis X-X of the shank member. Dimension III is the starting radius of the female threaded portion. - Referring to the cross-sectional detail view of an end portion of
shank member 72 shown inFIG. 12 , the axial forwardmost shank boreportion 116 is formed in a generally corresponding shape to forwardradial aligner portion 90 of thecutter member 70. Preferably, the diameter of the forwardradial aligner portion 90 is slightly larger than the diameter of the axial forwardmost shank boreportion 116. This difference in dimension between the diameters of the forwardradial aligner portion 90 and the axial forwardmost shank boreportion 116 provides an interference fit between thecutter member 70 and theshank member 72. The greater the extent of this interference fit, the greater the extent of stiffness, but too great of an interference fit will result in a reduction in the face contact between the flataxial stop shoulder 94 and theaxial stop shoulder 126 due to a distortion of the angular disposition of these shoulders, i.e., the flataxial stop shoulder 94 and theaxial stop shoulder 126. The extent of this interference fit (i.e., difference in diameters of the forwardradial aligner portion 90 and the axial forwardmost shank bore portion 116) can be termed “stand off”, and the “stand off” can range between about 0.015 and about 0.035 of the maximum diameter (CC) of thecutter member 70 with one preferable value of the “stand off” being equal to about 0.025 the maximum diameter (CC) of thecutter member 70. The “stand off” will close when the tool tightens due to the elastic deformation of the shank member. However, the dimensional relationship between the diameter of the forwardradial aligner portion 90 and the diameter of the axial forwardmost shank boreportion 116 may vary depending upon the specific application for the rotary cutting tool. - The shank bore 114 further contains an axial rearward shank bore
portion 140 that has an axial length “AAA” and a diameter “BBB”. The axial rearward shank boreportion 140 has a rearward shank borewall 144. The axial rearward shank boreportion 140 has a maximum diameter BBB. The shank bore 114, as well as the axial rearward shank boreportion 140, terminates at aterminal end 146. The angle at which the surface defining the axial rearward shank boreportion 140 is disposed relative to the central longitudinal axis X-X of theshank member 72 at an angle “DDD”. - In the specific embodiment shown in
FIGS. 8-15 , as will be seen by the values in Table 1, the fourth pitch P4 is greater than the third pitch P3. By utilizing a larger fourth pitch P4 in the female threadedbore portion 130 of theshank member 72, and thus a smaller third pitch P3 incutter member 70, the resulting stress on male threadedportion 100 ofcutter member 70 when coupled withshank member 72 is dispersed more evenly among the male threads (102, 104) as compared to an embodiment in which cooperating threads of generally the same pitch are utilized. In exemplary embodiments of the present invention, thread pitches varying from about 0.002 mm to about 0.010 mm between the respective threads of theshank member 72 andcutter member 70 have been employed. However, for cutter members with a diameter CC equal to 12 mm or 16 mm, one preferable difference in the pitch between the male threads and the female threads in the range of 0.003 mm and 0.005 mm (i.e., 3 to 5 microns). Typically, the difference resides in the pitch of the female threads being greater than the pitch of the male threads. In a specific embodiment of a 12 mm diameter cutter member, the pitch of the male threads is equal to 1.755 mm and the pitch of the female threads in the corresponding shank bore of the shank member is equal to 1.760 mm. In the specific embodiment of a 16 mm diameter cutter member, the pitch of the male threads is equal to 2.345 mm and the pitch of the female threads in the corresponding shank bore of the shank member is equal to 2.35 mm. In contrast to embodiments of the present invention, in instances where cooperating threads of generally the same pitch are utilized, stress is generally concentrated at the thread closest to flat axial stop shoulder due to the general inelasticity of the carbide or steel cutter. By more evenly distributing the stress among the threads (102, 104) of male threadedportion 100, specific embodiments of the present invention allow for higher loads to be applied to the connection before failure. - Assembly of the modular cutting tool assembly is performed by engaging the male threaded
portion 100 ofcutter member 70 with the female threaded bore 130 of theshank member 72 and subsequently rotating one or both of thecutter member 70 and/orshank member 72 until the forwardradial aligner portion 90 ofcutter member 70 is seated within the axial forwardmost shank boreportion 116 ofshank member 72 and theaxial stop shoulder 94 of thecutter member 70 abuts theaxial stop shoulder 126 of theshank member 72. The axial position ofcutter member 70 with respect toshank member 72 is derived from the direct contact ofstop shoulder 94 ofcutter member 70 with theaxial stop surface 126 ofshank member 72. Oncestop shoulder 94 and stopsurface 126 are engaged, the coupling is preferably further tightened to a specified torque using a torque limiting wrench to avoid excessive tension of thecutter member 70. In this position, therear end 70 of thecutter member 70 is spaced apart from theterminal end 146 of theshank bore 114. - The Table 1 sets forth the dimensional relationships of certain structural features of specific embodiments wherein one specific embodiment has a cutting diameter equal to 12 mm and the other specific embodiment has a cutting diameter equal to 16 mm. The length dimensions are set forth as a ratio of the specific dimension to the maximum diameter of the fluted cutter portion of the cutter member taken at the axial forward end of the cutter member, which is dimension CC in Table 1. The angular dimensions are set forth as angles.
-
TABLE 1 Dimensions for Specific Embodiments of the Cutter Member and the Shank Member For Length Dimensions, the range of the Ratio of the Dimension Relative to the Description of the Cutting Diameter (CC) of the Designation Designation/Dimension Cutter Member AA Half angle at which the surface of the 2° to 4° and wherein AA is axial forward radial aligner portion is greater than or equal to BB disposed relative to the central longitudinal axis W-W of the cutter member BB Half angle at which the distal surfaces 1° to 3° of the male threads of the male threaded portion are disposed relative to the central longitudinal axis W-W of the cutter member CC Maximum diameter of the fluted cutter 1.0 portion of the cutter member taken at the axial forward end of the cutter member (or cutting diameter) DD Maximum radial distance from the Ratio of DD/CC ranges between thread root to the centerline of the 0.30 to 0.35 threaded portion EE′ Radius of the arcuate fillet Ratio of EE′/CC ranges between 0.025 to 0.035 FF Axial length from the axial flat stop Ratio of FF/CC ranges between shoulder to the axial rear end of the 0.15 to 0.25 axial forward radial aligner portion GG Axial length between the axial flat stop Ratio of GG/CC ranges between shoulder and the rear end of the cutter 0.9 to 1.3 member HH Maximum diameter of the axial forward Ratio of HH/CC ranges between radial aligner portion, which is at the 0.75 to 0.85 axial forward end thereof MM Maximum diameter of the male Ratio of MM/CC ranges between threaded portion at the axial forward 0.72 to 0.82 end of the male threaded portion NN Angle of disposition between surfaces 20° to 40° of adjacent male threads in the male threaded portion OO Depth of the male threads Ratio of OO/CC ranges between 0.03 to 0.06 P3 Pitch of the males threads Ratio of P3/CC ranges between 0.12 to 0.18 QQ Half angle at which the roots of the 1° to 3° male threads of the male threaded portion are disposed relative to the central longitudinal axis W-W of the cutter member TT Half angle at which the axial 2° to 4° forwardmost cylindrical bore portion is disposed relative to the central longitudinal axis X-X of the shank member UU Half angle at which the second axial 1° to 3° forward cylindrical bore portion is disposed relative to the central longitudinal axis X-X of the shank member VV Maximum diameter of the axial Ratio of VV/CC ranges between forwardmost cylindrical bore section 0.75 to 0.85 WW Maximum diameter of the mouth of the Ratio of WW/CC ranges shank bore at the axial forward end of between 0.80 to 0.90 the shank bore XX Axial length between the axial forward Ratio of XX/CC ranges between end of the shank member and the rear 0.15 to 0.25 end of the axial forwardmost cylindrical bore section YY Axial length between the axial forward Ratio of YY/CC ranges between end of the shank member and the rear 0.2 to 0.3 end of the second axial forward cylindrical bore section ZZ Axial length between the axial forward Greater than the value for GG end of the shank member and the rear end of the shank bore AAA Axial length of the axial rearward Ratio of AAA/CC ranges cylindrical bore between 0.1 to 0.3 BBB Diameter of the axial rearward Ratio of BBB/CC ranges cylindrical bore between 0.50 to 0.75 CCC Maximum diameter of the second axial Ratio of CCC/CC ranges forward cylindrical bore section between 0.75 to 0.85 DDD Half angle at which the surface defining 1° to 3° the axial rearward cylindrical bore is disposed relative to the central longitudinal axis X-X of the shank member EEE Angle at which the opposed surfaces of 20° to 40° adjacent female threads are disposed relative to each other FFF Depth of the females threads Ratio of FFF/CC ranges between 0.03 to 0.06 GGG Half angle at which the roots of the 1° to 3° female threads are disposed relative to the central longitudinal axis X-X of the shank member III Starting radius of the female threaded Ratio of III/CC ranges between portion 0.37 to 0.43 P4 Pitch of the female threads Ratio of P4/CC ranges between 0.12 to 0.18 - Exemplary competitive cutter members are shown in
FIGS. 16 , 17 and 18.FIG. 16 is cutter made by Sandvik.FIG. 17 is a cutter member made by Iscar.FIG. 18 is a cutter member made by Fraiza. It is apparent that these competitors' cutter members have a different geometry than the specific embodiment herein. -
FIG. 19 is graph based upon results from a computer simulation showing the maximum principle stress (MPa) under preload at each of five different threads of four different cutter members whereinthread 1 is the thread closest to the cutting region of the cutter member andthread 5 is closest to the rear end (or tail) of the cutter member. The cutter member represented by the hollow circle and designated in the legend as “same pitch” has five threads and the pitch of the female threads of the shank member is equal to the pitch of the male threads of the cutter member. The cutter assembly represented by the solid square and designated in the legend as “1 micron” has five threads and the pitch of the female threads is 1 micron greater than the pitch of the male threads. The cutter assembly represented by the solid triangle and designated in the legend as “2 microns” has five threads and the pitch of the female threads is 2 microns greater than the pitch of the male threads. The cutter member represented by the solid circle and designated in the legend as “3 microns” has five threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads. Thethreads 1 through 5 designate the threads of the cutter member whereinthread 1 is the thread closest to the cutting region andthread 5 is closest to the rear end (or tail) of the cutter member. - Still referring to
FIG. 19 , as can be seen, the lower maximum principle stress values at thread Tare for the cutter members in which the pitch of the female threads is greater than the male threads, i.e., a difference of 2 microns and 3 microns. The maximum principle stress atthread 1 is higher for the cutter member in which the pitch of the female threads is 1 micron greater than the pitch of the male threads. The maximum pirnciple stress is greatest for the cutter member in which the pitch of the female threads is the same as the pitch for the male threads. Lower maximum principle stress values are preferred and especially atthread 1 which is the location most susceptible to breakage. There is not as great a concern about the maximum principle stress value atthread 5. -
FIG. 20 is graph based upon results from a computer simulation showing the maximum principle stress (MPa) under preload and bending at each of five different threads, if applicable, of six different cutter members as described below whereinthread 1 is the thread closest to the cutting region of the cutter member andthread 5 is closest to the rear end (or tail) of the cutter member. As will become apparent, each cutter assembly has a different number of threads and a different pitch condition, i.e., the difference in pitch between the female threads of the shank member and the male threads of the cutter member. - The solid circle (designated as “5 threads, 3 microns”) represents a cutter member with five threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads. The solid square (designated as “4 threads, 3 microns”) represents a cutter member with four threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads. The solid triangle (designated as “3 threads, 3 microns”) represents a cutter member with three threads and the pitch of the female threads is 3 microns greater than the pitch of the male threads. The open circle (designated as “5 same pitch”) represents a cutter member with five threads and the pitch of the female threads is the same as the pitch of the male threads. The open square (designated as “4 same pitch”) represents a cutter member with four threads and the pitch of the female threads is the same as the pitch of the male threads. The open triangle (designated as “3 same pitch”) represents a cutter member with three threads and the pitch of the female threads is the same as the pitch of the male threads.
- Still referring to
FIG. 20 , as can be seen, the lower maximum principle stress values atthread 1 are for the cutter members in which the pitch of the female threads is greater than the pitch of the male threads, i.e., a difference of 3 microns. The maximum pirnciple stress is greatest for the cutter member in which the pitch of the female threads is the same as the pitch for the male threads. Lower maximum principle stress values are preferred and especially atthread 1 which is the location most susceptible to breakage. There is not as great a concern about the maximum principle stress value atthread 5. - Although in the particular embodiments described herein the shank is provided with a threaded bore for engaging a complementary male thread on the cutter, the reverse is also possible whereby the shank is provided with a protruding male threaded portion, and the cutter is provided with an internally threaded bore.
- It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be tip embraced therein.
Claims (20)
1. A rotary cutting tool comprising:
a cutter member having an axial forward end and an axial rearward end, a cutting region at the axial forward end of the cutter member, and a male threaded portion adjacent the axial rearward end of the cutter member;
a shank member having an axial forward end and a shank bore opening at the axial forward end, the shank bore having an axial shank bore length, the shank bore containing a female threaded portion and an axial rearward shank bore portion axially rearward of the female threaded portion, and the axial rearward shank bore portion having a terminal end; and
when the male threaded portion of the cutter member fully engages the female threaded portion of the shank member, the axial rearward end of the cutter member being spaced a first distance axially forward of the terminal end of the axial rearward shank bore portion.
2. The rotary cutting tool according to claim 1 wherein the cutting region has a maximum diameter, and the cutter member has a central longitudinal axis.
3. The rotary cutting tool according to claim 2 wherein the cutter member comprises an axial forward radial aligner portion axially forward of the male threaded portion, and an axial stop shoulder axially forward of the axial forward radial aligner portion, and an arcuate fillet joining the axial forward radial aligner portion and the axial stop shoulder, and the arcuate fillet having a radius wherein the ratio of the radius of the arcuate fillet to the maximum diameter of the cutting region ranges between about 0.02 and about 0.04.
4. The rotary cutting tool according to claim 3 wherein the ratio of the radius of the arcuate fillet to the maximum diameter of the cutting region ranges between about 0.025 and about 0.035.
5. The rotary cutting tool according to claim 3 wherein the axial forward radial aligner portion has an axial rear end, and the axial stop shoulder is a distance from the axial rear end of the axial forward radial aligner portion (90), and the ratio of the distance to the maximum diameter of the cutting region ranges between about 0.15 to about 0.25.
6. The rotary cutting tool according to claim 5 wherein the ratio of the distance to the maximum diameter of the cutting region is greater than or equal to 0.18.
7. The rotary cutting tool according to claim 3 wherein the axial stop shoulder is disposed at an angle between about −3 degrees and about +3 degrees relative to a reference line perpendicular to the central longitudinal axis of the cutter member.
8. The rotary cutting tool according to claim 2 wherein the axial forward radial aligner portion has an outward facing circumferential surface disposed at an angle relative to the central longitudinal axis of the cutter member, and the angle ranges between about 1 degree and about 7 degrees.
9. The rotary cutting tool according to claim 8 wherein the male threaded portion comprises a plurality of male threads, and each of the male threads having a depth, a root and a distal surface, and the distal surfaces of the male threads being disposed at an angle relative to the central longitudinal axis of the cutter member wherein angle ranging between about 1 degree and about 3 degrees, the roots of the male threads being disposed at an angle relative to the central longitudinal axis of the cutter member wherein angle ranging between about 1 degree and about 3 degrees, and wherein the ratio of the male thread depth to the maximum diameter of the cutting region ranges between about 0.03 and about 0.06; and wherein the angle at which outward facing circumferential surface is relative to the central longitudinal axis of the cutter member is greater than or equal to the angle at which the distal surfaces of the male threads are disposed relative to the central longitudinal axis of the cutter member.
10. The rotary cutting tool according to claim 9 wherein the angle at which outward facing circumferential surface is relative to the central longitudinal axis of the cutter member is greater than the angle at which the distal surfaces of the male threads are disposed relative to the central longitudinal axis of the cutter member.
11. The rotary cutting tool according to claim 2 wherein the male threaded portion having a maximum radial distance from thread root to a centerline, and the ratio of the maximum radial distance from the thread root to the centerline to the maximum diameter of the cutting region ranges between about 0.30 and about 0.35.
12. The rotary cutting according to claim 1 wherein a difference between a maximum diameter of the axial forward radial aligner portion and the maximum diameter of the axial forwardmost shank bore portion ranges between about 0.015 and about 0.035 of the maximum diameter of the cutting region.
13. The rotary cutting tool according to claim 12 wherein the difference between a maximum diameter of the axial forward radial aligner portion and the maximum diameter of the axial forwardmost shank bore portion is about 0.025 of the maximum diameter of the cutting region.
14. The rotary cutting tool according to claim 1 wherein the male threaded portion comprises at least five male threads.
15. The rotary cutting tool according to claim 2 wherein the male threaded portion has a male thread pitch and the female threaded portion has female thread pitch, and the female thread pitch is greater than the male thread pitch.
16. The rotary cutting tool according to claim 15 wherein the ratio of the male thread pitch to the maximum diameter of the cutting region is between about 0.12 and about 0.18, and the ratio of the female thread pitch to the maximum diameter of the cutting region is between about 0.12 and about 0.18.
17. The rotary cutting tool according to claim 2 wherein the shank bore has an length, and the cutter member having a flat axial stop shoulder, a distance between the axial stop shoulder and the axial rearward end of the cutter member, and the length of the shank bore being greater than the distance between the axial stop shoulder and the axial rearward end of the cutter member, and the ratio between distance between the axial stop shoulder and the axial rearward end of the cutter member and the maximum diameter of the cutting region is between about 0.9 and about 1.3.
18. A cutter member for use in conjunction with a shank member wherein the shank member has an axial forward end and a shank bore opening at the axial forward end, the shank bore having an axial shank bore length, the shank bore containing a female threaded portion and an axial rearward shank bore portion axially rearward of the female threaded portion, and the axial rearward shank bore portion having a terminal end; the cutter member comprising:
an axial forward end and an axial rearward end, a cutting region at the axial forward end of the cutter member, and a male threaded portion adjacent the axial rearward end of the cutter member;
an axial forward radial aligner portion axially forward of the male threaded portion, and a flat axial stop shoulder axially forward of the axial forward radial aligner portion, and an arcuate fillet joining the axial forward radial aligner portion and the flat axial stop shoulder, and the arcuate fillet having a radius wherein the ratio of the radius of the arcuate fillet to the maximum diameter of the cutting region ranges between about 0.02 and about 0.04.
19. The cutter member according to claim 18 wherein the ratio of the radius of the arcuate fillet to the maximum diameter of the cutting region ranges between about 0.025 and about 0.035.
20. The cutter member according to claim 19 wherein when the male threaded portion of the cutter member fully engages the female threaded portion of the shank member, the axial rearward end of the cutter member being spaced a first distance axially forward of the terminal end of the axial rearward shank bore portion.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/273,456 US9643262B2 (en) | 2013-07-25 | 2014-05-08 | Coupling mechanism for cutting tool |
DE112015002167.1T DE112015002167T5 (en) | 2014-05-08 | 2015-05-06 | Coupling mechanism for cutting tools |
PCT/US2015/029408 WO2015171721A1 (en) | 2014-05-08 | 2015-05-06 | Coupling mechanism for cutting tool |
CN201580023534.9A CN106255564A (en) | 2014-05-08 | 2015-05-06 | Coupling mechanism for cutting element |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US13/950,407 US9643264B2 (en) | 2013-07-25 | 2013-07-25 | Coupling mechanism for cutting tool |
US14/273,456 US9643262B2 (en) | 2013-07-25 | 2014-05-08 | Coupling mechanism for cutting tool |
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US13/950,407 Continuation-In-Part US9643264B2 (en) | 2013-07-25 | 2013-07-25 | Coupling mechanism for cutting tool |
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US20150030399A1 true US20150030399A1 (en) | 2015-01-29 |
US9643262B2 US9643262B2 (en) | 2017-05-09 |
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US14/273,456 Active 2034-02-09 US9643262B2 (en) | 2013-07-25 | 2014-05-08 | Coupling mechanism for cutting tool |
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